High temperature extraction of spices and herbs

ABSTRACT

Principal components of herb or spice plant materials are simultaneously extracted and concentrated in at least one high temperature and pressure mechanical pressing step. The extract may be hydrated and then centrifuged to remove fine particulate solids and gums. A solution having several times the concentration of the pigments and flavor and aroma components of the starting raw material is obtained. The residual press solids and extract have significantly reduced bacterial counts as a result of the temperatures, high pressure, and high shear utilized, as well as the low moisture levels employed, thus producing not only a food grade extract but also a food grade residual solid having low bacterial counts and predictable, standardized levels of the principal components of interest. Additionally, edible antioxidants can be included in the process to enhance the stability of both the extract and the residual solids. The residual solids are ruptured in the process, giving rise to a quick-release and enhanced effect, and thus greater use effectiveness, when the herb or spice solids are used in foods or beverages.

FIELD OF THE INVENTION

The extraction of the principal significant components of herb and spiceplants containing pigment, flavor, and aroma and, when present in thestarting plant material, antioxidant.

Of especial interest is the extraction of the principal significantcomponents of spices and herbs represented by plants of the familyUmbelliferae, representatively celery, lovage, dill, carrot, fennel,cumin, caraway, parsley, coriander, angelica, and anise; Myrtaceae,representatively allspice and clove; of the genus Myristica,representatively mace and nutmeg; of the genus Piper, representativelyblack and white pepper; of the genus Sesamum, representatively sesameseed; the defining characteristic being that it is of such a spice orherb plant material from which flavor, aroma, color, and/or antioxidantcan be extracted and used to flavor and/or color foods and beverages orotherwise employed to enhance the palatability of foods and beverages.

BACKGROUND OF THE INVENTION AND PRIOR ART

Dried spices and herbs, most often in their ground form, are used in thepreparation of foods and beverages to add flavor, aroma, color, andpreservative properties that make the food or beverage more palatableand appealing. The dried spices, ground or unground, are usually addedto the food or beverage during the preparation at such a point in thepreparation that time is allowed for the principal components ofinterest to be extracted into the food or beverage to impart the desiredcombination of attributes to the food or beverage. Further, as spicesand herbs are notoriously known to have inconsistent levels of theflavor, aroma, color, or antioxidants, it is commonly required thatspices of varying levels of the principal components of interest beblended to make a final product that is consistent with regard to theprincipal components of interest to achieve predictable and repeatableperformance with respect to the flavor, aroma, color, or antioxidantrelease into the food or beverage system in which they are used. This isa costly and time consuming process.

As suggested in prior art, much of the flavor, aroma, and/or color oftenis not effectively transferred to the food or beverage. U.S. Pat. No.2,507,084 overcomes this obstacle of under-utilization of the principalcomponents of interest by first extracting the principal components ofinterest and subsequently coating the spent spice from the extractionprocess with a portion of the extract originally removed, therebyextending the useful amount of flavor and aroma that can be derived froma given quantity of spice. It is also disclosed that this processderives value from the exhausted spice solids, from which the flavor,aroma, color, or antioxidants have been removed, which would otherwisebe a waste product. This is a complicated and costly process forrecovery of the maximum value of the principal components of interest.

Traditional methods for the sterilization of ground spices and extractsinvolve the use of extremely toxic substances such as ethylene oxide ormethyl bromide, non-edible solvents which are inherently difficult toremove from the plant solids, irradiation, or steam and moisturetreatment to reduce plate counts to acceptable levels for use in foodsand beverages. Chemical sterilization, irradiation, and non-ediblesolvent extraction of spices are disagreeable to the consumer because ofthe perceived risks of residual chemicals and/or radiation remaining inthe plant matter and, as a result, several processes using addedmoisture, such as water or steam, at elevated pressures have beendeveloped as alternatives. Typical sterilization procedures aredisclosed in U.S. Pat. Nos. 4,210,678, 4,790,995, and 4,910,027. Allsterilization processes are inherently costly in that they require aseparate processing step or steps to accomplish the sterilization, andalso present the possibility of further degrading the more unstablecomponents. Addition of moisture or water vapor, as disclosed in U.S.Pat. Nos. 4,210,678 and 4,910,027, prior to or during the heating andsterilization process, results in a cooked aroma not typical of thefresh, dehydrated spice and also results in steam distillation and lossof some of the volatile flavor and aroma constituents.

Traditional extraction processes for the manufacture of concentratedextracts (concentrated several fold as compared with the raw material)involve not only the use of various non-edible solvent systems, but alsoa large proportion of solvent in relation to the compounds of interest.Many require the use of petroleum distillates, chlorinated solvents, orhighly flammable solvents which must be eliminated almost completelyfrom the finished products to make them safe for consumption. Thesesystems require expensive distillation equipment and special precautionsmust be taken to ensure worker safety and to limit environmental impact.The intensive processing required often destroys, modifies, or losessome of the more unstable compounds, delicate aromas, flavors, orpigments. More significantly, the last traces of undesirable non-ediblesolvents are very difficult to separate from the concentrated extract.The residual solid must necessarily contain the same residual non-ediblesolvents, which are removed only with difficulty. Such residual solventslimit the potential use of the residual solid for human consumption, andare potential environmental contaminants.

Other concentration techniques rely on high pressure equipment to obtaingood solvating properties from gases, e.g., liquid or supercritical CO₂(U.S. Pat. No. 4,490,398). High pressure liquefied or supercritical gasextraction requires expensive equipment and has limited solvatingabilities for some compounds requiring the addition of co-solvents, orsolvents such as propane and butane, which are also difficult to controland may be environmentally sensitive or undesirable in a finishedproduct.

Following extraction and desolventization, the concentrated extract isoften standardized with edible solvents and emulsifiers to provide aconcentrate with reproducible levels of the active or principalcompounds of interest to the user.

In an effort to overcome the shortcomings and risks associated with theabove-mentioned processes, extraction has been carried out using ediblesolvents such as vegetable oils or lard. Typical extraction proceduresare disclosed in U.S. Pat. Nos. 3,732,111; 2,571,867; and 2,571,948.These methods require a relatively large volume of solvent in relationto the compounds of interest and result in a dilute extract which islimited in its application and which has few of the advantages of theconcentrates which can be produced using volatile solvents.

U.S. Pat. No. 4,681,769 discloses a method for simultaneously extractingand concentrating in a series of high pressure countercurrent mechanicalpresses using relatively small amounts of vegetable oil as the solventin an attempt to overcome the problem of dilution inherent in earlierprocesses. This method suffers from severe limitations in temperatureand pressure ranges in an attempt to avoid unacceptable oxidativedamage, color loss, yield losses, and flavor changes with the finalresult being that contact times must be unduly extended for up to 16-24hours, adding greatly to the cost of the process. Extraction cycle timesare unduly long for a given size pressing operation, and the processdoes not provide for a controlled degree of browning or forsterilization of the extract or of the residual solid. It is alsolimited to temperatures of less than 100° F. Maximum pressures of up toabout 500 PSI (cone pressure) are claimed and this severely limits theefficiency and throughput rate for a given size pressing operation, asshown by the disclosure of this patent.

U.S. Pat. Nos. 4,790,995 and 4,910,027 require the addition of a coatingof animal protein to protect the spice from the loss of volatile aromacompounds during the sterilization process with water vapor. U.S. Pat.No. 4,210,678 requires bringing the moisture of the spice to above8-14%, in some cases up to 16-20%, and holding the spice for an extendedperiod of time prior to sterilization to equilibrate the moisture. Thisadditional step is costly and time consuming.

Above all, there is the unsolved problem of obtaining satisfactoryyields, quality, and throughput rates of acceptable extract and spiceand herb solids having an acceptable content of active principle withoutundesirable oxidative damage to, and reduced stability of, the principalcompounds of interest, while at the same time providing for simultaneoussterilization of both the spice or herb solid and extract.

Sesame oil is known to possess a unique combination of antioxidantsincluding gamma-tocopherol, sesamol and its precursors and/or reactionproducts such as sesamolin and sesamolinol, and sterols with anethylidiene side chain, such as delta-5 avenasterol and citrostadienolas described in EP 0,477,825 A2. As such, and as claimed in EP 0,477,825A2, it is useful as a stabilizing agent in other vegetable oils.However, it is disclosed in the aforementioned patent that "coldpressed" sesame oil is not as stable as solvent-extracted sesame oil andtherefore is not acceptable for the intended use.

EP 0,477,825 A2 states that sesame oil extracted by "cold pressing" isnot sufficiently resistant to oxidative deterioration and "is found notto be effective in the present invention; in a typical instance it wasfound to have a Rancimat value of only 3.4 hours." as compared to an RBDsesame oil with "a Rancimat value of 30.7 hours." This would severelylimit the utility of a prior art pressed oil but not one which has theeconomic advantage of being produced in the present process wherein nonon-edible solvents are used and the residual press cake solids havesignificant economic importance as they contain a portion of theprincipal components of interest at standardized levels and have notbeen adulterated or contacted by any non-food grade substance.

Obviously, existing prior art procedures leave much to be desired, andit is a primary objective of the present invention to provide aprocedure for the production of spice and herb products which havesignificantly reduced microbial counts in both the extract and residualsolids without the use of undesirable chemicals, irradiation, or highmoisture contents with the attendant uncontrolled browning and loss ofvolatiles. It is also an objective of this invention to produce a spiceor herb solid that will rapidly and efficiently release standardizedamounts of the principal components of interest into the food orbeverage in which it is used. It is also a primary objective of thepresent invention to provide a procedure for the production of spice andherb products having enhanced stability and which otherwise obviates theshortcomings of the prior art.

OBJECTS OF THE INVENTION

Accordingly, it is an object of the present invention to provide aprocess for simultaneously and rapidly extracting and concentrating theprincipal components of interest of a spice or herb plant material attemperatures of at least 215° F., preferably 215 to about 450° F., in aprocess which is completely free of petroleum, chlorinated or highlyflammable solvent, does not require high pressure gas handlingequipment, does not require solvent or distillation for solvent removal,and provides both an extract and a residual solid that are ofsignificantly reduced microbial activity and are free of adulterants andimpurities.

Another object of this invention is to prepare a residual solid or presscake that is standardized with respect to the principal components ofinterest, that when reground rapidly and efficiently imparts flavor,aroma, color, and/or other principal components of interest to a food orbeverage in which it is used, and all without the use of undesirablenon-edible solvents that are inherently difficult to remove from spicesolids remaining after extraction prior to standardization with respectto the principal components of interest, and in fact without thenecessity of using any solvent at all.

A further object of the invention is to provide such a process asfurther set forth under Summary of the Invention, wherein the spice orherb plant material contains lipids, oils, terpenes, or other edible"solvents" in amounts sufficient to effect extraction of the principalcomponents of interest without the use of added solvents.

BRIEF DESCRIPTION OF THE DRAWINGS

The FIGURE illustrates the process of the present invention, includingthe several process steps involved in the simultaneous high-temperatureextraction and concentration of herb or spice plant solids, to producethe desired extract and sterilized residual solid, both of reducedbacterial content and both of which can be readily standardized todesired levels of the principal components of interest. Although theprocess illustrated comprises three pressing stages, the number ofstages according to the invention is at least one and additionalpressing stages are optional, the exact number of pressing stages beingselected so as to effect the desired relative principal componentconcentration in the extract and in the residual solid.

SUMMARY OF THE INVENTION

The invention, then, inter alia, comprises the following, alone or incombination:

A high pressure pressing and extraction process for the production of aconcentrated edible extract and quick-release edible residual solids,both of reduced bacterial content, and both of which contain pigment,flavor, and aroma and, when present in the staring material,antioxidant, from solids of a herb or spice plant selected from thegroup consisting of Umbelliferae, Myrtaceae, Myristica, Piper, andSesamum, comprising the following steps:

subjecting said herb or spice plant solids to an extraction processinvolving at least one pressing stage to produce an extract and residualsolids,

separating the extract from the pressing stage,

separating the residual solids from the pressing stage, and

optionally subjecting the residual solids to a further pressing stage,

all pressing stages being carried out at a temperature of at least 215°F.; such a

process wherein the temperature is 215 to about 450° F.; such a

process wherein the solids are subjected to internal pressures in thepress stage(s) of at least 6,000 pounds per square inch; such a

process wherein the temperature is greater than 215° F.; such a

process wherein the moisture content of the starting solids is less than10% by weight, and wherein bacterial count reduction is effected at thislow moisture content, thereby avoiding undesirable loss of volatileflavor and aroma constituents and avoiding the development of cooked,off flavors and aromas which occur at higher moisture contents; such a

process wherein the solids extracted in the process are selected fromthe group consisting of celery, cumin, black pepper, sesame, mace,clove, coriander, and parsley; such a

process wherein fine particulate solids are filtered or centrifuged fromthe extract and alternatively discarded, returned to a mixing orpressing stage of the process, or incorporated in the final residualsolids; such a

process which includes the steps of hydrating the final extract to addwater to the extent of 5% to 200% by weight of the gums and fineparticulate solids therein and filtering or centrifuging to remove saidgums and solids; such a

process including the step of returning separated hydrated gums andsolids to the final residual solids; such a

process wherein an effective stabilizing amount of an edible antioxidantor chelator is introduced into the process; such a

process wherein the antioxidant comprises an antioxidant selected fromthe group consisting of lecithin, ascorbic acid, citric acid,tocopherol, ethoxyquin, BHA, BHT, TBHQ, tea catechins, sesame, and theantioxidant activity from an herb of the Labiatae family; such a

process wherein the antioxidant comprises a naturally-occurringantioxidant from an herb of the family Labiatae or powdered ascorbicacid; such a

process wherein the antioxidant comprises the antioxidant activity froman herb selected from the group consisting of rosemary, thyme, and sage;and such a

process wherein the temperature is between about 215° F. and 235° F.

Moreover, an extract of herb or spice plant solids produced according tothe process having a high level of principal flavor, aroma, color, orantioxidant components of interest and a low bacterial count due to thehigh temperature employed in its production and due to the low watercontent not greater than 10% in the starting herb or spice solids, and

an extract of herb or spice plant solids having a low bacterial countdue to the high temperature employed in its production and havingimproved stability due to the edible antioxidant therein producedaccording to the process, and

residual spice or herb plant solid having a low bacterial count due tothe high temperature employed in its production and having its tissueruptured so as to produce quick release of the flavor, aroma, color, orantioxidant component therein, and which is standardized with respect tothe principal flavor, aroma, color, or antioxidant component ofinterest, produced according to the process of the present invention.

THE PRESENT INVENTION

IN GENERAL

Raw spices, either ground (usually to pass U.S. 40 mesh, and preferablyto pass at least U.S. 20 mesh) or unground if coarse particles aredesired in the residual solid or cake, e.g., spice solids having amoisture range of about 0.15% to 10% by weight, preferably 1.5% to 10%by weight (ASTA method 2.0), are the starting materials for the processof the present invention.

Typical spice and herb starting plant materials include, Umbelliferae,representatively celery, lovage, dill, carrot, fennel, cumin, caraway,parsley, coriander, angelica, and anise; Myrtaceae, representativelyallspice and clove; of the genus Myristica, representatively mace andnutmeg; of the genus Piper, representatively black and white pepper; ofthe genus Sesamum representatively sesame seed; the definingcharacteristic being that it is such a spice or herb plant material fromwhich flavor, aroma, color, and/or antioxidant can be extracted and usedto flavor and/or color foods and beverages or otherwise employed toenhance the palatability of foods and beverages.

The comminuted or uncomminuted plant material is subjected to one ormore mechanical pressing stages, whereby a concentrated extract ofprincipal components is obtained and a final utilizable and preferablystandardized residual solid is produced.

According to the present invention, the spice or herb plant materialcontains lipids, oils, terpenes, or other edible "solvents" in amountssufficient to effect extraction of the principal components of interestwithout the use of added solvents. The parent spice or herb thusinherently contains vegetable oils at levels sufficiently high in theoriginal plant material to permit the effective extraction of theprincipal components of interest simply by pressing, so that theaddition of an edible solvent is not required for sterilization and toextract the principal components of interest and the spice or herb plantmaterial can therefore simply be exposed to one or more pressing stageswith the final extract being removed from each stage and not returned ina countercurrent flow. Thus all pressing stages are carried out in theessential absence of added solvent although, when an antioxidant isincluded in the process, it is frequently desirable to introduce theantioxidant in an edible solvent along with concomitant mixing, forbetter dispersion of the antioxidant throughout the plant solids,especially just ahead of one or more pressing stages. Such an amount ofedible solvent, when employed, is only a small percentage by weightcalculated on the weight of starting plant solids and, as such, may beemployed without interfering with the objectives and advantages of thepresent invention.

By varying the pressure, temperature, spice solids feed rate, and thenumber of mixing and pressing stages, the concentration of the principalcomponents can be controlled in both the extract and the residual solid.

As will be apparent to one skilled in the art, variations in the processof the present invention can be employed to produce variations inresult, the most advantageous of which are the production of bothextract of marketable potency and edible residual spice solids alsocharacterized by marketable potency and rapid release of the principalcomponents of interest.

For example, using ground celery seed of about 9% moisture and 22%extractable yield and 3% volatile oil, and leaving a residualextractable yield of 11% by weight of the starting spice, gives anextract of flavor strength that is equivalent to a hexane extract and aresidual cake solid that has a flavor level acceptable for many foodapplications without the undesirable residual solvents that are typicalof residual solids produced with organic solvents such as hexane. Byvarying the number of pressing stages and the internal pressures of thepressing stages, the residual solids can be standardized with respect tothe principal components of interest while at the same time providing anextract of marketable potency, with both the extract and residual solidshaving significantly reduced microbiological activity. The highpressures and high shear forces in the pressing stage(s) rupture thecell tissue of the plant material, thereby effecting quick release ofthe principal components of interest left in the residual solid andeffectively and dramatically increasing the utilization of the flavorand other principal components of the spice solid even though they arepresent at levels significantly below that of an untreated spice.

Although an edible solvent may be employed in the manner and to theextent indicated, extractable yields are in general in excess of 5% andvegetable oils are naturally present at levels sufficient to effectextraction of the principal components of interest and there is enoughoil in the original spice or herb to effectively permit an economicalextraction of the principal components of interest and recovery of theextract without added edible solvent.

Due to the treatment of high pressure and pressure relief, withpressures ranging from 6,000 to 30,000 psi in pressing stages of theoperation, and due to frictional heat generated in these high pressurezones, both the residual solid and the extract exiting the pressessurprisingly have a significantly reduced microbial load over that ofthe starting material even at moisture levels significantly lower thanthose indicated as being necessary by the prior art. Further,surprisingly and unexpectedly, the residual cake solids can in manycases be substituted directly, on a weight for weight basis, for theparent spice without any detectable reduction in flavor and aroma (orother principal component of interest) intensity even though they havesignificantly lower levels of these components. It is theorized that thehigh pressures, temperatures, and shear forces inherent in this processrupture the cell tissue making the compounds of interest much morereadily available for extraction and dispersion from the residual solidsinto the food or beverage system.

The extract from the first or any subsequent pressing stage may becentrifuged or filtered to provide the finished extract free ofparticulate solids. In some cases, the fine particulate solids and gumsin the extract may be hydrated to about 5% to 200% by weight of the gumsand solids prior to centrifugation or filtration to give a crystal clearextract. If water is not used to hydrate the solids and gums, the fineparticulate solids from the extract may conveniently be combined withthe final residual solids, recycled back into a pressing stage of theprocess, or alternatively removed from the process. If water is used tohydrate the solids and gums, it is preferred that the solids and gums beadded back to the final residual press solids or be removed from theprocess.

The small amount of edible solvent, if employed to disperse antioxidant,may be any edible solvent and especially one selected from the groupconsisting of soybean oil, corn oil, cottonseed oil, rapeseed oil,peanut oil, mono- , di-, or triglycerides, lecithin, edible essentialoils, sesame oil, edible alcohols, benzyl alcohol, propylene glycol,glycerine, hydrogenated or partially hydrogenated fats or oils,polyoxyethylene sorbitan esters, limonene, edible animal fats or oils,mixtures thereof, and edible derivatives thereof, the essential aspectsof the solvent when used being that it serves to disperse antioxidantand that it be edible.

The temperature to be employed during the processing and especially inthe press stages of the process of the invention may be varied widely,but the process is generally carried out at a temperature below about450° F., and between about 215° F. and 325° F., most preferably above215° F. and especially between about 215° F. and 275° F.

Temperatures in excess of 215° F. are advantageously employed to achieveacceptable yields and increased throughput rates as compared to priorart. Higher temperatures are employed, most importantly, to reduce themicrobial load of both the solids and the extract.

When an antioxidant or chelator is introduced into the process for theprotection of the spice being processed, this is preferably of theLabiatae family, such as rosemary, thyme, or sage, which is known forits protective antioxidant activity (U.S. Pat. No. 5,209,870), orsesame, or tea catechins, but may alternatively be a suitable edible andpreferably an approved food grade additive such as ethoxyquin, BHA, BHT,TBHQ, tocopherol, Vitamin C (e.g., as in U.S. Pat. Nos. 5,290,481,5,296,249, or 5,314,686), citric acid, EDTA, or the like. The process ofthe present invention is particularly adaptable to the extraction of anyspice or herb containing pigments and/or flavor, pungency, aroma, orantioxidants which impart those characteristics to a food with which itis combined.

DETAILED DESCRIPTION OF THE INVENTION

The following examples are given to illustrate the present invention butare not to be construed as limiting.

EXAMPLE 1

Celery Extraction, Flavor activation, and Pasteurization

Dried celery seed is ground in a hammermill and the resulting groundcelery (95% passing U.S. 40 mesh) is processed in a high pressureextraction system comprising one pressing stage, using an Egon KellerModel KEK-100 Screw Press. No edible solvent is added. The raw materialcelery seed is continuously fed at a rate of about 300 lbs per hour witha total contact time in the pressing stages of about 15 to 120 seconds.The pressing stage is operated at about 20,000 psi internal pressure andabout 215 to 235° F., which is maintained by cooling with water orheating with steam through the bore of the press shafts as needed.

The starting extractable yield of the ground celery is about 23.7% byexhaustive soxhlet extract with hexane, the volatile oil content isabout 1.7% by ASTA method 5.0. The aerobic plate count of the raw spiceis 63,000,000 (Analysis run according to Bacterial Analytical manual ByAOAC, 8th edition, 1995, and ISO-GRID Methods Manual, 3rd edition, 1989)and the moisture content is 9.7% by ASTA method 2.0.

The principal components of interest in both the extract and theresidual solids are phthalides (Sedanenolide and N-Butyl phthalide) andvolatile oils, which account for a significant portion of the flavor andaroma of the spice. The phthalide area count by HPLC (using a reversephase, C-18 column and an isocratic solvent mixture of 47%acetonitrile/53% water) of the soxhlet extract from the raw spice is131,682. The resulting final extract from the pressing process has aphthalide area count of 127,248 and a volatile oil content of about7.3%. The reground celery residual solids have an extractable yield bysoxhlet of 11% and a volatile oil content of about 0.68%. This clearlydemonstrates that the flavor and aroma components of the raw spice canbe effectively extracted using high pressure, high temperaturemechanical pressing without any solvent other than the naturallyoccurring oils in the spice.

The aerobic plate count of the extract is 1,200, and 200,000 for thefinal residual solid exiting the press. This clearly demonstrates,surprisingly and contrary to prior art, that the plate count of a spiceand its extract can be very significantly reduced at such low moisturecontents.

The flavor profile of the resulting celery residual cake solids iscompared to a sample of ground celery seed manufactured by McCormick &Co., Inc. (Extractable yield of 28.3%). Four grams each of the residualsolids and the ground celery seed were extracted for 20 minutes in 100ml of ethanol in a 100 ml Erlenmeyer flask immersed in water in asonicator to model the release of the principal flavor of the spice in afood system. The filtered ethanol extracts were further diluted to1/5000 dilutions in water for flavor evaluation. Triangle tests weredone on the samples. The samples were coded with random three-digitnumbers and twelve expert panelists were asked to pick the sample thatwas different compared to the McCormick ground celery seed. Six of thetwelve panelists could not pick the residual celery cake solids as beingdifferent from the untreated ground celery seed with respect to flavorprofile and intensity. By statistical analysis (according to methodsdescribed in Sensory Evaluation Techniques, Vol. II, by MortenMeilgaard, 1987, page 133), this clearly and surprisingly demonstratesthat there is no significant difference in flavor intensity and profilebetween the commercial unextracted ground celery seed and the residualcake solids, from which more than 1/2 the extractable yield has alreadybeen removed. This clearly demonstrates that the high shear, hightemperature process of the present invention effects quick andsignificantly more efficient release of flavors in a food system,thereby effectively and dramatically increasing the utilization of theflavor components of the spice even though they are present at levelssignificantly below that of an untreated spice. This is contrary toexpectations and overcomes, with a simple and economical process, theobstacles disclosed in the prior art.

EXAMPLE 2

Cumin Extraction, Flavor Activation, and Pasteurization

Cumin seed at 8% moisture is processed in the same manner as given inExample 1. The starting ground cumin had an extractable yield of 28.5%,a volatile oil content of 2.0%, and an aerobic plate count of 9,000,000.The last traces of suspended solids with the solids being returned andcombined with the residual solid cake exiting the press. The regroundresidual solids had an extractable yield of 11.5%, a volatile oilcontent of 0.41%, and an aerobic plate count of 85,000. Triangle testswere performed on the residual solids in the same manner as given inExample 1 except that they were compared to the ground starting cuminseed. Seven of twelve panelists could not pick the residual cumin cakesolids as being different from the untreated, ground starting material.This clearly demonstrates that the high shear, high temperature processeffects quick and significantly more efficient release of flavors in afood system in a consistent and predictable way while at the same timesignificantly reducing the bacterial counts at moisture contents belowthose required in prior art.

EXAMPLE 3

Black Pepper Extraction, Flavor Activation, Pasteurization, andStandardization

Unground Black Pepper berries at 3% moisture, 21% extractable yield, 12%piperine, and 5% volatile oil were extracted in a two-stage pressingoperation. The aerobic plate count was 68,000,000. The piperine levelswere established using ASTA method 12.1. The presses were operated at30,000 PSI internal pressure and 250-275° F. with the temperatures beingmaintained by cooling with water or heating with steam through the boreof the press shafts as needed. The extract was collected from eachpressing stage and centrifuged to remove the suspended solids with thesolids removed being returned to the final press cake residual solids.

The piperine content of the final press cake solids was 6.1%, thevolatile oil content was 3.25%, and the aerobic plate count was1,800,000. The combined final extract from both pressing stages was 52%piperine, 11.6% volatile oil, and had an aerobic plate count of 230.

By varying the pressure of the pressing stages between 10,000 and 30,000PSI the piperine content of the residual press cake solids wascontrolled between 10.5% and 6.0%, demonstrating that the piperinecontent of the residual solids can be standardized at specific levels ofthe principal compound of interest, in this case, piperine which isresponsible for the pungency of black pepper. This overcomes thedifficulty of obtaining a spice solid with consistent and predictablelevels of the principal components of interest without the complicatedprocess of using a non-edible solvent extraction process,desolventization of the spice solids and extract, and dispersing of aportion of the final extract back onto the residual solids as disclosedin prior art.

The residual cake solid, reground to pass 20 mesh, at 6% piperine wascompared to a ground, unextracted commercial grade black pepper at 6%piperine by extracting both samples in ethanol for 20 minutes using theprocedure described in Example 1. The percentage of piperine extractedin this model food system for each sample was determined by measuringthe absorbance of the filtered ethanol solution from each sample. 85% ofthe piperine was extracted from the residual cake solids and only 45%was extracted from the unextracted commercial grade black pepper.

This clearly demonstrates that residual press solids release theprincipal components of interest much more rapidly and efficiently intoa food system, thereby significantly improving the utilization of thespice. Further, surprisingly and contrary to prior art, the plate countsof both the solids and the extract were very significantly reduced atsuch low moisture contents.

EXAMPLE 4

Extraction, Antioxidant Addition, and Pasteurization of Sesame Seed

Sesame oil is known to possess a unique combination of antioxidantsincluding gamma-tocopherol, sesamol and its precursors and/or reactionproducts such as sesamolin and sesamolinol, and sterols with anethylidiene side chain, such as delta-5 avenasterol and citrostadienolas described in EP 0,477,825 A2. As such, and as claimed in EP 0,477,825A2, it is useful as a stabilizing agent in other vegetable oils.However, it is disclosed in the aforementioned patent that "coldpressed" sesame oil is not as stable as traditionally solvent-extractedsesame oils and therefore is not acceptable for the intended use.

Dehulled, whole sesame seed at 6% moisture, 48% extractable yield, andan aerobic plate count of 2,500,000 is extracted in a two-stage pressingoperation with the presses being operated at about 6,000 and 20,000 PSIinternal pressures respectively and with temperatures of the cakeexiting the presses being maintained at about 225° F. using theprocedures generally described in previous Examples except that anantioxidant blend containing 29% lecithin, 20% powdered ascorbic acid,5% citric acid, 15% tocopherol, and 1% rosemary extract (in accordancewith Chang and Wu U.S. Pat. No. 5,077,069) is dispersed on the sesameseeds prior to pressing at a level of 0.1% by weight of the startingplant material. The antioxidant blend, prior to dispersion on the sesameseed, is dispersed in an equal volume of edible oil, in this case sesameoil from a previous extraction. This aids in the dispersion of theantioxidant.

The extracts from both pressing stages are combined and hydrated withdistilled water at about 75% by weight of the acetone-insoluble mattercontained in the combined extracts. The hydrated mixture is thencentrifuged to remove the gums and suspended solids with said gums andsolids being returned to the residual press cake solids exiting thesecond pressing stage.

The cake exiting the final pressing stage had an extractable yield of15% and an aerobic plate count of 15,000. The final oil was crystalclear and had an aerobic plate count of 500. This clearly demonstratesthe effectiveness of the extraction and a very significant reduction inplate count at low moisture contents contrary to prior art.

The test was repeated with all conditions being the same except that noaddition of antioxidant was included in the process. The unprotectedsesame oil thus produced, along with a sample of a commerciallyavailable hexane-extracted RBD sesame oil, are compared to oil producedwith the antioxidant blend using a 679 Rancimat™. In this method, thestability of a particular oil is compared to the stability of anuntreated control held at controlled temperatures while air is bubbledthrough the sample at 18 liters per minute. The induction time ismeasured by a sharp change in conductivity of a solution into which air,blown through the oil sample, is passed. The oil is maintained at 120°C. By plotting conductivity versus time, a sharp inflection point isobserved which is indicative of rapid deterioration of the oil andproneness to rancidity.

In this example, the untreated pressed oil control had an induction timeof 3.5 hours. A sample of the pressed oil produced with the addition ofthe antioxidant mixture had an induction time of 32 hours. A sample ofthe hexane-extracted RBD oil had an induction time of 30 hours. Thisclearly demonstrates that the inclusion of antioxidants can improve thestability of both the extract and the residual cake solids produced bythe present process, providing a sesame oil having stability that isequal to or greater than RBD (refined, bleached, and deodorized) sesameoil and certainly much improved over a control produced withoutantioxidant addition. This is contrary to conventional wisdom asdisclosed in EP 0,477,825 A2.

Other suitable antioxidants (e.g., lecithin, butylated hydroxy anisole(BHA), butylated hydroxy toluene BHT, tertiary butyl hydroxy quinone(TBHQ), tea catechins, Labiatae herb antioxidants, finely dividedascorbic acid, tocopherol, and citric acid can be substituted in wholeor in part for the specific antioxidant mixture employed with similardesirable protective results, preferably a naturally occurringantioxidant from an herb of the Labiatae family, e.g., rosemary, sage,or thyme, or powdered ascorbic acid.

EXAMPLE 5

Extraction, Activation, and Pasteurization of Mace

Mace, chopped in a hammermill to pass U.S. 20 mesh, at 8% moisture, 55%extractable yield, 8% volatile oil, with an aerobic plate count of99,000,000 was extracted in a two-stage pressing operation using theprocedure given in Example 4.

The extracts from both pressing stages were combined and the fineparticulate solids were removed by centrifuging. The fine particulateswere returned to the cake exiting the second pressing stage. The finalextract had an aerobic plate count of 1,500, again demonstrating thatsignificant reduction in bacterial counts can be achieved at such lowmoisture contents contrary to prior art.

The final residual press solids had an extractable yield of 20%, avolatile oil content of 2%, and an aerobic plate count of 15,000,clearly demonstrating that the plate count can be reduced at such lowmoisture contents, contrary to prior art.

A triangle test was performed as described in Example 1 and the residualpress solids were compared to a retail grade ground mace with anextractable yield of 35% and a volatile oil content of 6%. Seven oftwelve trained panelists could not pick the press residual solids asbeing different from the retail ground mace with regard to flavorintensity, even though the retail grade contained significantly moreextractable yield and volatile oil. This clearly demonstrates that thehigh shear, high temperature pressing operation of the inventionsignificantly improves the flavor release characteristics of the spiceand that much higher utilization of the principal flavor compounds canthus be achieved.

EXAMPLE 6

Extraction, Activation, Standardization, and Pasteurization of Clove

Clove, ground to pass U.S. 20 mesh, at 9% moisture, 22% extractableyield, 18% volatile oil, with an aerobic plate count of 95,000,000 isextracted in a single-stage pressing operation using procedure as givenin Example 1.

The fine particulate solids are removed from the extract bycentrifuging. The fine particulates were returned to the cake exitingthe press. The final extract had an aerobic plate count of 1,000, againdemonstrating that significant reduction in bacterial count can beachieved at such low moisture contents contrary to prior art.

The final residual press solids have an extractable yield of 12%, avolatile oil content of 12%, and an aerobic plate count of 15,000,clearly demonstrating that the plate count can be reduced at such lowmoisture contents, contrary to prior art.

A triangle test is performed as described in Example 1 and the residualpress solids are compared to unextracted ground clove with anextractable yield of 17% and a volatile oil content of 12%. Six oftwelve trained panelists are not able to pick the press residual solidsas being different from the unextracted ground clove even though theunextracted clove contains significantly more extractable yield. Thisclearly demonstrates that the high shear, high temperature pressingoperation of the invention significantly improves the flavor releasecharacteristics of the spice and much higher utilization of theprincipal flavor compounds can thus be achieved.

EXAMPLE 7

Extraction, Activation, Standardization, and Pasteurization of Parsley

Parsley seed at 8% moisture is processed in the same manner as given inExample 1 except that the pressing stage is operated at about 10,000PSI. The starting ground parsley has an extractable yield of 22.5%, avolatile oil content of 2.2%, and an aerobic plate count of 25,000,000.The extract exiting the press is centrifuged to remove the last tracesof suspended solids with the solids being returned and combined with theresidual cake solids exiting the press. The reground residual solidshave an extractable yield of 14.0%, a volatile oil content of 1.2%, andan aerobic plate count of 500,000. The extract has an aerobic platecount of 1,500. Triangle tests are performed on the residual solids inthe same manner as given in Example 1 except that they are compared tothe ground starting parsley seed. Six of twelve panelists cannot pickthe residual parsley cake solids as being different from the untreated,ground starting material. This clearly demonstrates that the high shear,high temperature process effects quick and significantly more efficientrelease of flavors from an herb in a food system in a consistent andpredictable way while at the same time significantly reducing thebacterial count at moisture contents below those considered necessary bythe prior art.

EXAMPLE 8

Extraction, Activation, Standardization, and Pasteurization of Coriander

Coriander seed, ground to pass U.S. 20 mesh, at 7% moisture, 19%extractable yield, 6% volatile oil, with an aerobic plate count of16,000,000 is extracted in a single-stage pressing operation usingprocedure as given in Example 1.

The final residual press solids had an extractable yield of 10%, avolatile oil content of 3%, and an aerobic plate count of 45,000. Thefinal extract, after centrifuging to remove the fine particulate solids,had an aerobic plate count of 1,000. This again clearly demonstratesthat bacterial plate counts can be very significantly reduced atmoisture contents below those disclosed by prior art.

By varying the pressure of the pressing process between 6,000 and 30,000PSI, the extractable yield in the final residual press solids was variedfrom about 12% down to 5%, demonstrating that the levels of residualyield in the cake solids can be readily standardized to consistentlevels even though the levels in the starting unextracted spice may varysignificantly, thereby providing a spice with consistent flavorintensity comparable to that of an unextracted ground spice to the enduser. This allows the food manufacturer or end consumer to achievepredictable levels of flavor release in a food or beverage system,overcoming the difficulty previously presented by spices in generalwhere the levels of the principal compounds of interest varyconsiderably with weather conditions for a given crop year, source ororigin, and storage conditions and duration.

It is thereby seen that an improved process for the extraction andsterilization of spice and herb plant solids, whereby improved yields ofboth extract and residual solids are obtained, whereby both the extractand the residual solids have improved color stability and freedom frombacterial contamination due to the higher temperatures employed, wherebyan extract in the form of a clear solution can be obtained by removal ofgums and particulate solids in the form of their insoluble hydrates,whereby even greater color stability can be effected by the employmentof edible antioxidants, all without the expected disadvantages fromemploying higher temperatures and lower water content as clearlyindicated by the prior art, and whereby all of the stated objects of theinvention have been accomplished, has been provided.

It is to be understood that the invention is not to be limited to theexact details of operation, or to the exact compositions, methods,procedures, or embodiments shown and described, as obvious modificationsand equivalents will be apparent to one skilled in the art, and theinvention is therefore to be limited only by the full scope which can belegally accorded to the appended claims.

I claim:
 1. A high pressure pressing and extraction process for theproduction of a concentrated edible extract and tissue-rupturedquick-release edible residual solids, both of reduced bacterial content,and both of which contain pigment, flavor, and aroma and, when presentin starting material, antioxidant, from starting solids of a herb orspice plant selected from the group consisting of Umbelliferae,Myrtaceae, Myristica, Piper, and Sesamum, comprising the followingsteps:subjecting said starting herb or spice plant solids to anextraction process involving at least one pressing stage to produce anextract and residual solids, separating the extract from the pressingstage, separating the residual solids from the pressing stage, andoptionally subjecting the residual solids to a further pressing stage,all pressing stages being carried out at a temperature of at least 215°F. wherein solids are subjected to internal pressures in the pressstage(s) of about 6.000 pounds per inch to about 30,000 pounds persquare inch, and wherein starting solids have a moisture content lessthan 10% by weight, and wherein bacterial count reduction is effected atthis low moisture content, thereby avoiding undesirable loss of volatileflavor and aroma constituents and avoiding development of cooked, offflavors and aromas which occur at higher moisture contents.
 2. processof claim 1, wherein the temperature is up to about 450° F.
 3. A processof claim 1, wherein the solids extracted in the process are selectedfrom the group consisting of celery, cumin, black pepper, sesame, mace,clove, coriander, and parsley.
 4. A process of claim 1, wherein fineparticulate solids are filtered or centrifuged from the separatedextract and alternatively discarded, returned to a mixing or pressingstage, or incorporated in the final residual solids.
 5. A process ofclaim 1, which includes the steps of hydrating separated extract to addwater up to 5% to 200% by weight of gums and fine particulate solidstherein and filtering or centrifuging to remove said gums and solids. 6.A process of claim 5 including the step of returning separated hydratedgums and solids to residual solids.
 7. A process of claim 1, wherein aneffective stabilizing amount of an edible antioxidant or chelator isintroduced into the process.
 8. A process of claim 7, wherein theantioxidant comprises an antioxidant selected from the group consistingof lecithin, ascorbic acid, citric acid, tocopherol, ethoxyquin, BHA,BHT, TBHQ, tea catechins, sesame, and the antioxidant activity from anherb of the Labiatae family.
 9. A process of claim 8, wherein theantioxidant comprises a naturally-occurring antioxidant from an herb ofthe family Labiatae or powdered ascorbic acid.
 10. A process of claim 9,wherein the antioxidant comprises antioxidant activity from an herb ofthe family Labiatae selected from the group consisting of rosemary,thyme, and sage.
 11. A process of claim 1, wherein the temperature isbetween about 215° F. and 275° F.